Course Title: Testing and certification of EVs

(EV702)

Module: 1
Prepared by: Dr. Gaurav Ninawe
 Module I: Introduction to Testing of EVs

• Technology Scenario, Market Scenario, Policies and Regulations, Payback and commercial model,

Polices in India, opportunities. Specification & Classification of Vehicles (including M, N and O layout),

Homologation & its Types, Regulations overview (EEC, ECE, FMVSS, AIS, CMVR), Type approval

Scheme, Homologation for export, Conformity of Production, various Parameters, Instruments and

Types of test tracks, Hardware in The Loop (HIL) concepts for EV/HEVs.
 What is Electric Vehicle
Testing?
• Due to the pandemic, we have already seen how disruptions and delays in raw materials can decrease
different distributors’ inventory levels. Assuming that many external concerns will be alleviated, product
development and testing are internal aspects that more directly reflect how organizations can adapt to the
requirements for EV testing.

• Testing these sophisticated vehicles is just as important as it is for conventional vehicles, but the different
software and components involved will require different steps and infrastructure to be addressed. In
addition, there are standards in different stages of life that will affect EV testing, even more so as new
standards are developed.

• All of these considerations are active concerns as the automotive world still strives toward evolution to
autonomy. To properly support the EV ecosystem with continuous EV testing, these are the questions and
concerns that will need to be addressed within the industry to maintain stability and growth throughout the
future.
 How Can Electric Vehicle Testing be
Defined?
• Before expanding on the importance of EV testing and some of the opportunities and challenges involved, it
is best to define it. Simply put, EV testing involves testing electric vehicle models, not only at the full-vehicle
level but also at a component level.

• With the proper testing facilities, organizations should be able to integrate their EV, decompose it down to
different subsystem and component levels, and perform different tests as required by their previously
established requirements.

• In other words, EV testing should address both functional and functional safety testing, relative to its
functional requirements. Depending on what level that organizations are testing, the infrastructure and level
of integration will be different.
Why Evs?
 What Are the Different Electric Vehicle
Standards?

• Electrification is a process that has been around for decades. The history of the electric vehicle (EV) extends
as far back as the 19th Century, and the world has witnessed different waves of growth since then. The
current growth in EV ownership suggests a new direction in modern transportation, one the industry hopes
to take to the next level.

• OEMs have been introducing new electrified vehicles in their inventory, emphasizing that electrification is a
prominent focus for the industry and will continue to be as the trend continues to grow. Governments and
subject matter experts (SMEs) collaborate to develop electric vehicle standards, ensuring a dependable EV
market with reduced risks and hazards.

• EV standards will be one of many determining factors that help companies prioritize safety and guarantee
the reliability of their products. The industry must maintain compliance with EV standards—especially as
these EV systems become more complex—to advance modern transportation safely.
 Federal Motor Vehicle Safety
Standards
• The Federal Motor Vehicle Safety Standards (FMVSS) are standards administrated by the National Highway
Traffic Safety Administration (NHTSA), which is a government agency part of the U.S. Department of
Transportation (USDOT). FMVSS focuses on establishing regulations pertinent to design, performance, and
durability.

• One example of FMVSS standards is No. 305. This standard specifies performance requirements for battery
packs, addressing electrolyte spillage. High-voltage batteries must be isolated from low-voltage, especially in
the case of crash events.

• Companies can test this isolation because there are systems in place that monitor the isolation of high-
voltage to low-voltage. This is one example of several FMVSS-required compliance standards that apply to EV
and hybrid vehicle production.
 SAE
• Another group of standards is the Society of Automotive Engineers (SAE) International standards, put in
place to advance the engineering involved with vehicular mobility.

• SAE standards are voluntary practices and are often considered recommended guidelines. One example
would be SAE J2990/2_202011, titled “Hybrid and Electric Vehicle Safety Systems Information Report.” This
overlaps with the isolation requirements referenced in FMVSS No. 305, but this SAE report further addresses
enclosures, labels, and identifications.

• Since dealing with a high amount of voltage can be hazardous, it is key to have labels on manual switches
that disconnect and de-energize the high-voltage system so that you are not solely relying on software.

• Essentially, this report educates companies on high-voltage electric propulsion vehicle safety systems so that
they are aware of the potential hazards.
 ISO
• In addition, the International Organization for Standardization (ISO) is a global organization that develops
standards in collaboration with several countries.

• A predominantly known standard, ISO 26262, focuses on the safety of vehicles, including EVs. Some ISO
standards apply to electrical safety, like ISO 17409, developed to help minimalize shock hazards within high-
voltage testing. In EV performance testing, some standards include ISO 12405, ISO 18243, and ISO 15118.

• The international Electrotechnical Commission (IEC) is an organization that develops standards

internationally for anything electrical and electronic. IEC 61851 is a standard that addresses electromagnetic
compatibility (EMC) and electromagnetic interference (EMI) testing, ensuring that a company’s systems are
not susceptible to conducted emissions. Both ISO and IEC standards are agreed upon by SMEs but are not
legally required.
 SAE J2990/2_202011

• SAE J2990/2_202011 is also similar to another SAE recommended guideline: J2990_201907, “Hybrid and EV
First and Second Responder Recommended Practice.” Though not mandatory, this practice addresses the
hazards of any potential EV-related car accident.

• When a crash occurs, the high-voltage system needs to be deactivated within a certain amount of time so
that the first responders can properly help those involved in the incident.

• Understanding the shock hazards present in high-voltage applications is critical, especially for vehicle crash
detection and automatic shutdown purposes, because not having that knowledge can lead to harmful
events.
 List of Testing & Homologation Rules for
Electric Vehicles in India
• As India embraces the transition towards sustainable mobility, electric vehicles (EVs) are gaining
significant momentum. To ensure the safety, performance, and compliance of EVs, the Indian
government has established testing and homologation rules. This guide will help manufacturers,
stakeholders, and consumers understand the essential requirements and procedures. Let’s
explore the regulations that govern the EV industry in India.

• Testing and homologation are crucial processes that ensure the safety, reliability, and compliance
of electric vehicles. Through rigorous testing, manufacturers can identify and rectify any potential
issues, guaranteeing the quality of their vehicles. Homologation certifies that EVs adhere to the
prescribed standards and regulations, instilling confidence in consumers and facilitating the
growth of the sector.
 List of Testing & Homologation Rules for
Electric Vehicles in India
• In India, several rules and procedures govern the testing and homologation of electric vehicles.
Let’s explore some of the key requirements:
• CMVR Compliance:
• Electric vehicles need to comply with the Central Motor Vehicles Rules (CMVR) set by the Ministry
of Road Transport and Highways. These rules cover various aspects such as safety, emissions,
registration, and vehicle operation.
• AIS Standards:
• Automotive Industry Standards (AIS) established by the Automotive Research Association of India
(ARAI) define the technical requirements for EVs. It includes guidelines for components such as
batteries, chargers, electrical safety, and performance.
• ARAI Certification:
• The Automotive Research Association of India (ARAI) conducts testing and certification of electric
vehicles. ARAI certification ensures compliance with safety and performance standards specified
by the Indian government.
• ICAT Approval:
• The International Centre for Automotive Technology (ICAT) is another authorized agency for
testing and certification of electric vehicles in India. ICAT approval validates compliance with
Indian regulations and standards.
• Electromagnetic Compatibility (EMC) Testing:
• EVs undergo EMC testing to assess their immunity to electromagnetic interference. This testing
ensures that the vehicle’s electrical and electronic systems function properly without interference
from external sources.
• Battery Safety Testing:
• Electric vehicle batteries undergo rigorous testing to ensure their safety and performance. These
tests evaluate parameters such as thermal stability, overcharge protection, short circuit
prevention, and durability.
• Crash Testing:

• EVs are subjected to crash tests to assess occupant safety and structural integrity. These tests
evaluate the vehicle’s ability to protect occupants during various crash scenarios.

• Performance Testing:

• Testing of EVs includes performance evaluation parameters such as range, acceleration, top
speed, and energy efficiency. These tests provide accurate information to consumers regarding
the vehicle’s capabilities.

• Noise and Emissions Testing:

• EVs must comply with noise and emissions regulations. Although EVs produce zero tailpipe
emissions, noise levels generated by their components need to be within acceptable limits.
 Specification & Classification of Vehicles (including M,
N and O layout),
• Vehicle Classification:
• Vehicles are typically classified based on various criteria such as size, weight, purpose, and design.
Common classifications include:
• Passenger Vehicles: Cars, SUVs, vans, etc., designed primarily for transporting passengers.
• Commercial Vehicles: Trucks, buses, and vans used for transporting goods or passengers for hire.

• Layout Classifications:
• The layout classification system categorizes vehicles based on their arrangement of wheels and
axles. The most common layouts are:
• M Layout: Motor vehicles with at least four wheels, typically designed for road use. This includes most
passenger cars and trucks.
• N Layout: Motor vehicles with at least four wheels, designed for off-road use or special purposes such
as construction equipment or military vehicles.
• O Layout: Trailers and semi-trailers designed to be towed by M or N layout vehicles
• Further Classification Based on Purpose and Size:
• Light Vehicles: Generally, vehicles under a certain weight limit designed primarily for personal
use, including cars and light trucks.
• Heavy Vehicles: Trucks, buses, and other large vehicles designed for commercial or industrial use.
• Special Purpose Vehicles: Vehicles designed for specific functions such as firefighting, agriculture,
mining, etc.

• Specifications:
• Dimensions: Length, width, height, wheelbase, and track width.
• Weight: Gross vehicle weight rating (GVWR), curb weight, payload capacity.
• Performance: Engine power, torque, fuel efficiency, acceleration, top speed.
• Safety Features: Airbags, stability control systems, braking systems.
• Emissions: Compliance with emission standards (e.g., Euro standards).
• Technology: Infotainment systems, connectivity features, driver assistance systems.
 Homologation & its Types,

• Homologation is the process of certifying that a particular vehicle is roadworthy and matches certain specified
criteria laid out by the government for all vehicles made or imported into that country. Essentially, the tests ensure
that the vehicle matches the requirements of the Indian market in terms of emission and safety and road-worthiness
as per the Central Motor Vehicle Rules. For Homologation purposes, vehicles are categorized as:

• Category A: Means a Category Agricultural Tractor Power tillers are included in this category.

• Category C: This is Construction Equipment Vehicle (CEV).

• Category L1: Means a motorcycle with maximum speed not exceeding 45 km/h and engine capacity not exceeding
50cc if fitted with thermic engine or motor power not exceeding 0.5 kilo watt if fitted with electric motor.

• Category L2: Means a motorcycle other than Category L1.

• Category L3: Means a two wheel motorcycle with an engine cylinder capacity in the case of a thermic engine
exceeding 50 cm3 or whatever the means of propulsion a max. design speed exceeding 50 km/h. with more then 50
cc and speed of more then 50 kmph
 Homologation & its Types,
• Category L5M: Means a L5M category-Passenger carrier (Auto rickshaw) and Gross vehicle Weight is equal to 1500
kilograms.
• Category L5N: Means a motorcycle other than Category L1.
• Category M: Means a motor vehicle with at least four wheels used for the carrying passengers.
• Category M1: Means a motor vehicle used for the carriage of passengers, comprising not more than eight seats in
addition to the driver's seat.
• Category M2: Means a motor vehicle used for the carriage of passengers, comprising nine or more seats in addition to
the driver's seat and having a maximum Gross Vehicle Weight not exceeding 5 tons.
• Category M2G: Means a motor vehicle used for the carriage of passengers, comprising nine or more seats in addition
to the driver's seat and having a maximum Gross Vehicle Weight not exceeding 5 tons and Having addition Off road
(Cross country vehicle) capabilities.
• Category M3: Means a motor vehicle used for the carriage passengers, comprising nine or more seats in addition to
the driver's seat and having a maximum Gross Vehicle Weight exceeding 5 tons.
• Category M3G: Means a motor vehicle used for the carriage passengers, comprising nine or more seats in addition to
the driver's seat and having a maximum Gross Vehicle Weight exceeding 5 tons and Having addition Off road (Cross
country vehicle) capabilities.
 Homologation & its Types,
• Category N: Means motor vehicles having at least four wheels used for the carrying goods which may also carry
persons in addition to the goods subject to conditions.
• Category N1: Means a motor vehicles used for carriage of goods and having a Gross vehicle Weight not exceeding 3.5
tons.
• Category N2: Means a motor vehicles used for carriage of goods and having a Gross vehicle Weight exceeding 3.5 tons
but not exceeding 12 tons.
• Category N3: Means a motor vehicles used for carriage of goods and having a Gross vehicle Weight exceeding 12 tons.
• Category T: This is all about Trailer Category, It is used for the carrying goods.
• Category T1: Means a Trailer used for carriage of goods and having a Gross vehicle Weight not exceeding .75 tons.
• Category T2: Means a Trailer used for carriage of goods and having a Gross vehicle Weight exceeding .75 tons but not
exceeding 3.5 tons.
• Category T3: Means a Trailer used for carriage of goods and having a Gross vehicle Weight exceeding 3.5 tons but not
exceeding 10 tons.
• Category T4: Means a Trailer used for carriage of goods and having a Gross vehicle Weight exceeding 10 tons.
• Category T5: Means A semi Trailer intended to be drawn by a three wheeled haulage tractor.
 The Vehicle Homologation
Process
• Type Approval: The process of vehicle homologation in India begins with type approval. Manufacturers
need to submit their vehicles to the ARAI for testing and certification. The ARAI evaluates various
aspects such as safety features, emission levels, performance, and compliance with relevant regulations.

• Testing and Certification: The ARAI conducts rigorous testing to assess the vehicle's compliance with
safety and performance standards. It includes crash tests, emission tests, noise tests, and other
necessary evaluations. If the vehicle meets all the requirements, it receives certification indicating its
compliance.

• Documentation: Manufacturers must submit a comprehensive set of documents along with the vehicle
for homologation. These documents include technical specifications, design drawings, safety features,
and test reports. The ARAI reviews these documents to ensure that they are accurate and complete.
 The Vehicle Homologation
Process
• Inspection of Manufacturing Facilities: The ARAI also conducts inspections of the
manufacturing facilities to verify if the production processes are in line with the prescribed
quality standards. This step is crucial to ensure consistency in the manufacturing of vehicles
and to prevent any deviation from the certified design.

• Batch Testing: In addition to the initial type approval, the ARAI also conducts periodic batch
testing to ensure that the vehicles produced by the manufacturer continue to meet the
prescribed standards. It ensures that the vehicles' quality and safety are maintained
consistently over time.
 Regulations Governing Vehicle
Homologation
• Central Motor Vehicles Rules (CMVR): The CMVR is the primary regulation governing vehicle
homologation in India. It outlines the technical and safety standards that vehicles must meet. The CMVR
covers various aspects such as construction, dimensions, safety features, emission limits, noise limits,
and more.

• Bharat Stage Emission Standards (BSES): India follows the Bharat Stage emission standards, which are
based on European emission standards. These standards regulate the emission levels of vehicles to
control air pollution. Vehicle homologation ensures that vehicles meet the specific BSES requirements.

• Automotive Industry Standards (AIS): The AIS are a set of standards issued by the Ministry of Road
Transport and Highways in India. These standards cover different aspects of vehicle design,
performance, and safety. They provide detailed specifications for components such as lighting systems,
braking systems, seat belts, and more. Vehicle homologation ensures compliance with the relevant AIS
for each component.
 Regulations Governing Vehicle
Homologation
• Crash Test Regulations: The ARAI conducts crash tests to assess the structural integrity of vehicles in the
event of a collision. The crash test regulations define the specific requirements for frontal impact, side
impact, and pedestrian protection. Homologation ensures that vehicles pass these tests and provide
adequate protection to occupants and pedestrians.

• Electrical Safety Standards: Vehicle electrical systems must meet specific safety standards to prevent
electrical hazards and ensure proper functioning. These standards cover aspects such as wiring, connectors,
batteries, and electrical protection devices. Homologation ensures that vehicles comply with these safety
standards.
 Conformity Of
Production(COP) for emission
• The test agency randomly selects a vehicle at specified
periodicity from the factory.
• Running in, and servicing prescribed in the manual are
carried out on this vehicle under the supervision of the test
agency.
• Emission tests (mass emission and tail pipe emission) are
carried out by the test agency.
• COP provisions provide for extended trials and recall in the
case of failure
• Presently COP procedure is limited to only emissions We
plan to introduce for components in future 2~3 years
26
 NATRAX
• The National Automotive Test Tracks (NATRAX) Project

• NATRAX is an automotive testing and certification centre that was developed under the
National Automotive Testing and R&D Infrastructure Project (NATRIP) under the aegis of the
Ministry of Heavy Industries and Public Enterprises. The project is built on 4,140 acres of
land at a cost of Rs. 1,321 crore (US$ 177.07 million) in Pithampur, Indore, Madhya Pradesh.

• NATRAX was launched with an aim to offer world-class evaluation and testing services for all
vehicular categories, ranging from 2-3 wheelers to heavy commercial vehicles with national
and international standards. Under this programme, the government hoped to foster the
Indian automotive industry to develop indigenous, safe and high-performance vehicles.
• The centre comprises 16 testing tracks, with 12 operational tracks as follows:
• High-speed Track
• Dynamic Platform
• Braking Track
• Gradient Track
• Fatigue Track
• Gravel and Off-road Tracks
• Handling Track
• Comfort Track
• Handling Track for 2-3 wheeled vehicles
• Sustainability Track
• Wet Skid Pad
• Noise Track
 HARDWAREIN-THE-LOOP(HIL)
In recent years, with the development of computer technology, hardwarein-the-
loop(HIL) simulation technology is used by design and test engineers to
evaluate and validate components during the development of EV. HIL
simulation test platform can test the performance of powertrain, evaluate the
pros and cons of control strategy, narrow the study scope and find the
breakthrough rapidly. Because of HIL simulation playing an irreplaceable role
in the development of EV, it needs to be well understood and pay increasing
attention
 HIL

HIL simulation is a modern technique that is used in the development and test of complex real-
time embedded systems. Rather than testing components in complete system setups, HIL
simulation allows the testing of new components and prototypes while communicating with
software models that simulate the rest of the system [1]. The purpose of building a HIL
simulation platform is to provide all of the electrical stimuli needed to fully exercise the
electronic control unit (ECU). The accuracy of the simulation and its electrical interfacing to the
ECU must be such that the ECU ‘thinks’ it is controlling the real system. So, engineers can
observe the performance of the ECU functionality under a variety of conditions, with the
conditions being programmed into the system
•Thank You